Offset-Notch Channel Nut for Shear-Resistant Strut Interlock
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Solution Overview
Problem
Existing channel nuts struggle to effectively resist shear forces while maintaining low manufacturing effort and versatility, particularly when interacting with strut channels that have inclined or non-toothed lips.
Innovation Solution
The channel nut features non-aligned notches on its flanges, forming a curved seat for the strut channel's lip, which induces local bending and deformation for a robust interlock, and can be manufactured with integral metal parts using a sheet metal process, allowing for easy installation and resistance to shear forces without additional toothing on the strut channel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional straight grooves or meandering shapes are used in channel nuts, then manufacturing effort increases or shear force resistance decreases, but the channel nut can engage with strut channel lips
Solution Approach 1:
The patent applies curvature by forming a curved seat in the flange that corresponds to the curved profile of the strut channel lip. This curved geometry enables effective engagement and shear force resistance without requiring complex meandering shapes or additional toothing, thus maintaining ease of manufacture while improving strength
Solution Approach 2:
The patent employs asymmetry by providing different groove configurations in the two flanges - the first flange has a first groove while the second flange has a second groove with different characteristics. This asymmetric design allows optimization for specific loading conditions while maintaining manufacturing simplicity
2Strength
If toothing is added to strut channel lips to improve interlock, then shear force resistance increases, but manufacturing effort and complexity increase
Solution Approach 1:
Instead of adding toothing to the strut channel lip (the conventional approach), the patent inverts the solution by providing the engaging features in the channel nut itself through curved seats and grooves. This maintains the simplicity of the strut channel while achieving the desired interlock performance
Solution Approach 2:
The patent segments the engagement function into separate components - the curved seat provides the primary engagement geometry while the grooves provide secondary engagement features. This segmentation allows each feature to be optimized independently without adding overall complexity to the strut channel
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design provides a channel nut that efficiently resists shear forces and is easy to manufacture and install, accommodating various strut channel lip configurations with enhanced engagement and versatility.
Implementation Method 1
the first lip of the strut channel is pressed into the curved and therefore non-corresponding first seat provided by the first notches, local bending and/or deformation will occur, which can provide a particularly efficient interlock between the channel nut and the channel
Implementation Method 2
this interlock can also resist shear forces directed parallel to the strut channel and its lips in a particularly efficient manner
Data Source
AI summary
A channel nut includes a web, a first flange projecting from the web where the first flange has a first notch for receiving a first lip of a strut channel, and a second flange projecting from the web where the second flange has a first notch for receiving the first lip of the strut channel. The first notch of the first flange and the first notch of the second flange are arranged in a non-aligned relationship with respect to each other such that the first notch of the first flange and the first notch of the second flange form a curved first seat for the first lip of the strut channel.